Method of producing glass fibers



Feb. 4, 1941. G, SLAYTER 2,230,272

METHOD OF PRODUCING GLASS FIBERS 5 Sheets-Sheet 1 Filed Aug. 4, 195aINVENTOR. Games filcz yter;

A TTORN Feb. 4, 1941. G. SLAYTER 2,230,272

METHOD OF PRODUCING GLASS FIBERS Filed Aug. 4, 1938 s Sheets-Sheet. 2

' IN V EN TOR. Games filiayter;

A TTORN Feb. 4, 1941. G. SLAYTER METHOD OF PRODUCING GLASS FIBERS FiledAug. 4, 1938 3 Sheets-Sheet 5 INVENTOR. Games lqyten ATTORN S.

Patented Feb. 4, 1941 UNITED STATES PATENT OFFICE Games Slayter, Newark,

Ohio, assignor, by mesne assignments, to Owens-Coming FiberglasGorporation, Toledo, Ohio, a corporation of Delaware Application August4, 1938, Serial No. 223,104

10 Claims.

The present invention relates to a novel method for producingcorrugated, wavy or crimped fibrous glass and tangled or felted mats ofcrimped fibrous glass.

The present invention also relates in part to a novel method ofattenuating a multiplicity of glass fibers by mechanical means andsimultaneously producing a twisted yarn thereof.

Heretofore attempts have been made to produce crimped fibrous glass, butthe methods of production were limited to those used ordinarily formechanically drawing fibrous glass and the glass was crimped as anintermediate step while the glass was in a formative stage.Synchronization between the attenuating means, the crimping rolls andthe temperature means had to be made.

The fibrous products made by this mechanical drawing process consistedof layers of fibers lying on top of one another more or less parallelwith the major surface of the mat. The corrugated fibers were corrugatedin but one plane so that the fiber would lie fialt and pile up in thatform. There was no entanglement or felting of the glass fibers, nor werethere fibers running in directions transverse to the stratifications orlayers.

An object of the invention is to produce a fibrous glass productconsisting of crimped fibers wherein the glass fibers may be entangledand felted to produce a product having vastly increased resilience inall directions, compressibility, lightness in weight and mass integrity.

Owing to the crimped nature of the fiber, an entanglement or felting isdifficult to achieve, for it will be noted that the fibers possesssubstantial dimensions in more than one direction. It is thus difiicultfor a crimped fiber to penetrate through small interstices present inthe fibrous mass.

Another object of the present invention is to produce crimped glassfibers at extremely high speeds comparable with and even superior tothose achieved by the steam blown process illustrated and described inthe copendingapplication of John H. Thomas and myself as inventors,Serial Number 704,028, filed December 26, 1933, which has matured intoPatent No. 2,133,236 dated October 11, 1938.

Still another object of the invention is to produce crimped glass fibersby my novel method and apparatus and simultaneously provide means forlubricating the fibers as they are being attenuated.

Still another object of the invention is to provide a method andapparatus for producing crimped fibers wherein conditions may becontrolled for producing various fiber diameters, according to thenature of the product desired. It is also an object to permit adjustmentof conditions whereby a varying degree of crimp may be imparted to thefiber and also, if desired, all crimp may be dissipated before final setof the glass fiber.

A further object is to produce fibrous glass which lies in one or moreplanes; that is, the fiber may be corrugated in but one plane or thefiber may be twisted in addition to lie in a multiplicity of planes andextend in substantially all directions.

An ancillary object of the invention is to attenuaxte fibrous glassmechanically by means of two coacting traction surfaces which do notpinch, squeeze or crush the fibers therebetween as they are attenuatingthe same.

Still another ancillary object of the present invention is to providecrimping rollshaving a gearshaped formation, which are mechanicallyindependent from one another and yet move in synchronism at extremelyhigh speeds. When operating at high speeds the fibers should be able tofree themselves from each of the rolls tangentially without wrappingthemselves about one or the other.

Another object is to provide a novel synchronous drive for the rollswhich is not limited to speeds attainable by a mechanical linkage orconnection.

Another object of the present invention is to provide, if desired, meansfor cooling the glass streams at or shortly after they have left theorifice outlet openings of the supply body. The mode of attenuation maythus utilize the invention illustrated and described in the BritishPatent No. 482,085.

Various other objects and advantages of the present invention willbecome apparent from the following description taken in conjunction withthe drawings, in which:

Fig. 1 is an elevational view, shown in part diagrammatically, of anapparatus for producing crimped fibrous glass and forming, if desired, amat thereof;

Fig. 2 is a cross-sectional view of a portion of the apparatus shown inFig. 1, the section being so taken along the line 11-11 of Fig. 1;

Fig. 3 is an elevational view of a modified embodiment of the presentinvention adapted to produce crimped fibrous glass;

Fig. 4 is a cross-sectional view of the apparatus shown in Fig. 3, thisview being taken along the line IV-IV of Fig. 3;

Fig. 5 is a fragmentary elevational view of a stream of glass beingattenuated and crimped by means of coacting gear-shaped members;

Fig. 6 is a diagrammatic cross-sectional view which illustrates amodified embodiment of the present invention, showing the crimpedfibrous glass being thrown out under conditions to cause the glassfibers to entangle with one another and treated with a coating materialprior to their deposition in bat form;

Fig. 7 is an elevational cross-sectional view of another modifiedembodiment of the present invention, showing means for lubricating thefibrous glass prior to complete attenuation;

Fig. 8 is a diagrammatic elevational view of apparatus for attenuatingfibrous glass and simultaneously forming th same into a twisted yarn;and

Fig. 9 is a diagrammatic plan view of a modified embodiment of thepresent invention.

The present invention contemplates the simultaneous mechanicalattenuation and crimping of a glass stream into wavy fibrous form bymeans of suitable apparatus such as coacting gearshaped members. Theindividual teeth of the respective gears or crimping rolls are made torun interjacent although spaced apart from one another. Clearance isthus provided to permit the glass streams or fibers to pass therethroughwithout being crushed or squeezed. Suflicient traction may be imparted,however, to the fiber as it passes in zigzag formation, that attenuationmay be efiected without excessive wear or friction upon the coactingcrimping rolls.

After being attenuated, the crimped glass fibers may be fabricated intosuitable products as desired. For example, they may be depositeddirectly upon a belt and built up into mat formation. To facilitate aninterfelting, I have discovered that twisting and/or entanglement of thfibers prior to deposition is beneficial, and for this purpose, atemperature control whereby the glass emerging from the crimping rollsis still in a partially plastic or formative stage, is desirable. Whenthe glass is still in a partially plastic stage as it emerges from therolls, and the fibers are permitted by means of turbulence, or extremelyhigh speeds of formation, to twist and tangle with one another, thefibers after depositing upon the belt, or prior thereto, may be chilledand set in their twisted or tangled formation. In this connection, thecrimped fibers may be deposited upon a conveyor in partially plasticcondition, or rendered plastic thereafter, and then worked, compressedor compacted into felted form of predetermined density and dimensions.

Referring now more particularly to Figs. 1 and 2, reference character l0designates a glass feeder appurtenant to a glass tank or other supplybody. The design of this feeder may be as desired, although satisfactoryresults have been achieved by means of a feeder illustrated anddescribed in the Thomas and Fletcher Patent No. 2,165,318. Located belowthe feeder in may be, if desired, a blower or other cooling apparatus lI suitable to facilitate attenuation in accordance with the BritishPatent No. 482,085. The blower ll, however, may be or may not be usedaccording to the type of stream forming apparatus which isto be used.

Spaced below the feeder l0 and the blower II, are coacting crimpingrolls l3 and I4. respecttively, having a gear-shaped cross-section thatare provided with a series oi teeth, or bails I5, around the peripherythereof. Each of the crimping rolls l3 and I4 is keyed to shafts I3 andII respectively, which in turn are mounted upon supports l3 and I3respectively. The support It is pivoted at its lower end upon acantilever beam 23 by means of a pin 23* The support i3 is also fixedupon the cantilever beam 23 at its lower end, and is held in fixedposition at the upper end by cantilever beam 2 I. The cantilever beams20 and 2| may be bolted to a slide member 22,adapted to slide verticallyupon a base or framework 23. A rack 24 fixed to the slide member 22coacts with a spur gear 25 which may be rotated to adjust the rack andappurtenant mechanism in predetermined vertical position, The gear 25may be borne by a lug 26 secured to the base 23 by means of bolts 21.

The crimping rolls l3 and I4 are actuated by any suitable powermechanism, such as a motor 30, and at synchronous speeds whereby therespective teeth l5 of the crimping rolls intermesh without engaging ortouching each other.

A suitable interconnecting mechanism may consist of a gear box 3|, apulley 32, belt 33, and pulley 34, leading to gear trains communicatingwith the respective crimping rolls. The gear trains are all drivensynchronously from the pulley 34 which is fixed to or integral with agear 35.

The gear 35 drives the crimping rolll4 through intermediate gear 31 andgear 33 which is keyed to the shaft ll of the crimping roll l4.Intermediate gear 31 may be mounted upon the support IS.

The gear 35 drives the crimping roll l3 through gear 40, intermediategear 4|, and gear 42 which is keyed to the shaft l6 of the crimping rolll3. Intermediate gear 4| is mounted upon the pivoted support l8.

Mechanism for holding the crimping roll l3 at any predetermined distancefrom the crimping roll l4, includes a set screw 45 located on the innerside of the support is, and adapted to abut the support [8. The setscrew 45 may be adjusted to permit the crimping rolls to come togetherto any desired degree.

Mounted upon the support I3 is a plate having upstanding flanges 5|between which is a pivoted finger 52, fulcrumed upon pivot 53. Thefinger 52 at one end is provided with a roughened thumb plate 54 whichmay be pressed to throw the opposite end of the finger out of alignmentwith the support I! and thus enable the crimping rolls to be movedtogether in operative position. When it is desired to move the crimpingroll l3 out of operative position, a handie 55 integral with the supportl8 may be pulled out and the finger 52 turned to be in alignment withand abut the support l9. The finger 52 thus holds the crimping roll l3out of operative position with the crimping roll l4.

Spaced below the crimping rolls [3 and I4 is a bat forming unitconsisting of a traveling support or conveyor upon which the crimpedfibers descend and deposit themselves in a mat formation. A hood GI maybe provided to direct the fibers upon the conveyor 60. If desired, thefibers may be compressed by means of a caterpillar belt 62 mounted overthe mat and conveyor 60 and, if desired, into the mouth of the hood.

In operation of this device the two crimping rolls are drivensimultaneously and in complete synchronism with one another from thecommon driving gear 35. The crimping roll l3. may be pulled into and outof engagement with the crimping roll ll during operation of the gearsand without interrupting their mutual synchronism. This, it will beobserved, is done by causing the crimping roll I3 and cooperatingdriving mechanism which is mounted upon the support l8 to pivot aboutthe pin or shaft 20. Pulling the support l8 and the crimping roll I3into inoperative position does not affect the intermeshing of the geartrains.

The apparatus illustrated and described in Figs. 1 and 2 is ideallysuitable for producing crimped fibers of what might be considered arelatively coarse type, that is having a diameter in the ordinary rangesof about .001 to .1 inch, this type of fiber being particularlyadaptable for air filtration media although obviously suitable also forheat and sound insulation, etc. While high speeds of production may beused, the mechanical difficulties encountered in the use of gear trains,generally limit the speed of attenuation of the fibrous glass below thatdesirable for highest speed and finest fiber formation. For thispurpose, I have designed a high speed apparatus controlled solely byelectrical means, reference being made in Figs. 3 and 4.

In Figs. 3 and 4, reference character 65 designates a fiber glass feederadapted to provide a multiplicity of glass streams 68. Spaced below thefeeder 65 are coacting crimping rolls 0? and 88 respectively, eachprovided with a series of crimping teeth 89 around the periphery thereofadapted to intermesh with one another. The crimping roll 0? is keyed toa motor shaft E0 of a motor H. The crimping roll 08 is keyed to asimilar motor shaft 12 of a motor 13. Motor 13 is bolted to a verticallyadjustable base plate 115 having an aperture l6 therein for the passageof the fibers i8 emerging from the crimping rolls.

Motor H is mounted upon a horizontal slide 79, sliding in the slidechannel 80 which is bolted to the base plate 75. Screw 82 fixed at oneend to the slide 19 by means of 9. lug 83, may coact with an internallythreaded member or nut 83, mounted upon the base plate 75 by means of alug 85. A crank 86 is fixed to the free end of the screw 82, and may berotated either way in order to move the slide I9 and crimping roll 6'!to any desired distance from the crimping roll 80. Vertical movement maybe imparted to the base plate 15 by means of vertical screw posts 88upon which the base plate is mounted. The vertical screw posts 88 areall interconnected with one another by means of a chain 89 and sprockets89 to operate synchronously. The screw posts may be driven by anysuitable means such as bevel gears 90 and Si, actuated by drive shaft 92(see Fig. 3). Supplementary guide posts 95, passing through the baseplate 15, may be provided to contribute strength and steadiness to themechanism.

Each of the crimping rolls 6'! and 68 may be provided with a housing I00and IM respectively. The housings fit around the crimping rolls andcommunicate at their upper ends with opening I03 on each side of the rowof streams 66. As the crimping rolls rotate, the crimping teeth 69 carryair therebetween which is thrown out centrifugally to the top of thehousing so that it passes out through the opening I03 where it isdirected upon the glass streams 68. The drafts or blasts of air emergingfrom the openings l 03 may induce more air over the top of the openingagainst the glass as it emerges from the feeder 65.

An oil spray l0 l may be provided in either one or both of the housingsI00 and llll to incorporate an oil fog or vapor into the air streampassing through the blower I03. The glass streams 66 and resultingfibers may thus be lubricated by oil or other suitable lubricant priorto physical contact either with other fibers or by the crimping rollsthemselves.

The motors II and I3 may be of any suitable design, although preferablythey are of a synchronous motor type, such as conventional synchronousmotors or reluctance motors, and they may be synchro-tied with oneanother in order to insure absolute synchronism of the crimping rollsduring operation irrespective of the speed of attenuation. When usingordinary synchronous motors, or synchronous reluctance motors, they mayeach be electrically connected to a common source of high frequencycurrent, such as a motor-generator, electron tubes, spark gaps or thelike, although a high frequency motor-generator is to be preferred.Extremely high motor speeds are attainable by this type of drive, as forexample, about 20,000 or 40,000 R. P. M. or even more. With crimpingrolls of about one to two feet circumference, a total attenuating speedof 20,000 to 80,000 or more lineal feet of fiber length per minute maybe achieved. The fiber diameter produced by such a mechanism may varyaccording to requirements, although ordinarily the fiber diameter of afew microns or ten thousandths of an inch to about a thousandth of aninch is suitable for ordinary purposes, such as heat insulating bats,blankets, or the like. Ordinarily, crimped fibers having several timesthe diameter of straight fibers may be used without increasing physicalirritation or affecting deleteriously the feel or flexibility of theproduct. For this reason, coarser crimped fibers of say .001 inch maymore successfully be used for a great many purposes than straightfibers.

In addition, varying types of products may be produced by adjustingconditions, principally the temperatures at which the fibers passthrough the crimping rolls. If the glass has been chilled below whatappears to be the softening point prior to the delivery in the gears,the fibers pass through in the usual zigzag formation but straighten outagain as they emerge from the rolls.

Such a formation is illustrated diagrammatically in Fig. 8 where it willbe noted that a fiber H0 is passing downwardly between the crimpingrolls Ill and H2 respectively, and then emerges again as a straightfiber H3. Such fibers may be fabricated as desired as, for example, theymay be deposited upon a belt and accumulated in mat formation thereon.If desired, they may be fabricated directly into a yarn by wrapping themupon a rotating drum, as illustrated in British Patent No. 482,085. Ifdesired, a multiplicity of such fibers H3 emerging from rolls ill and H2may be simultaneously twisted and packaged by an internal winding into arotating bucket H4.

If the temperature conditions of the glass streams as they pass throughthe crimping rolls is sufficiently high so that the glass after emergingfrom the rolls is above what appears to be the softening point, or atleast is still in a formative stage, the fibers are free to twist andbend so that ultimate fibers having portions of their length insubstantially all directions may be produced. Such a process isillustrated diagrammatically in Fig. 6. These fibers i8 produce a noveltype of pack in that they tangle themselves in the gaseous atmosphere, aresult not attainable when they are merely laid upon one another on afiat surface. In addition, the fibers extending in all directions arepartially tangled or prefelted, another condition dimcult to achieve bymerely laying fibers upon a surface since the fibers having crimps lyingin all planes are difilcult to penetrate into the interstices betweenthe fibers in the mat.

As shown in Fig. 6 the crimped fibers 18 tangle and twist in the gaseousatmosphere below the crimping device and then deposit themselves freelyupon a continuously moving surface or conveyor IIG to form a highlyresilient mat III. A hood I I8 may be used to confine the deposition toa predetermined surface upon the conveyor H6. If desired, rolls H9 maybe provided to increase the interfelting of the fibers. These rolls maybe driven in the direction of the arrows, or may be what is known asidler rolls.

Fig. 6 also illustrates a lubricant or binder applicator I20 adapted tospray a suitable treating material I2I upon the fibers as they descendand deposit themselves upon the belt I Hi. The binder may be of anysuitable composition such as natural'or artificial resins, includingboth the thermoplastic and thermosetting type, glue, asphalt, casein,sodium silicate, starch, plaster of paris, borax, oil, fatty acids,soluble and/or insoluble soap, rubber, latex, linseed oil, agar agar,oils, fats, clay, bentonite, pitches, gums, or combinations thereofaccordingto the properties desired.

In Fig. 7 a modified embodiment of the present invention is showncomprising crimping rolls I23 and B24 intermeshing with one another,housings I25 and I26 over the crimping rolls respectively, guide skirtsI21 and I28 arranged under the crimping rolls respectively to facilitateemission of the crimped fibers, and a lubricant spray gun I29 having itsnozzle located directly over the point of intermeshing of the crimpingrolls. Such an arrangement of the spray gun I29 permits a lubricant tobe applied to the glass fibers prior to and as they enter the crimpingrolls to insure minimum friction or scratching of the fibers, andprevent premature wearing of the rolls.

In Fig. 9 I have diagrammatically illustrated another arrangementwhereby individual motors other than electrically synchro-tied motorsmay be used. In Fig. 9 reference characters I30 and I3I designateintermeshing crimping rolls keyed to motor shafts I32 and I33,respectively, of motors I34 and I35, respectively. 0n each motor shaftI32 and I33 is keyed a synchronizing gear I36 and I31; respectively,intermeshing with one another. The synchronizing gears I36 and I31 causethe crimping rolls I30 and I3I to continually intermesh with one anotherwithout touching or engaging the respective teeth. With such anarrangement it is possible to use ordinary high speed induction motorsor any other type of electrical motor as desired.

It will be noted that the load carried by the synchronizing gears I36and I31 is relatively light since the two motors inherently operate atsubstantially identical speeds. If desired, one of these motors may beeliminated and only one motor used to provide power to both crimpingrolls via intermeshing gears I36 and I31.

Various modifications and variations may be resorted to within thespirit and scope of the present invention as defined in the appendedclaims.

I claim:

1. The method of producing crimped fibrous glass which comprises flowinga stream of molten glass, cooling the same to a viscous stream, applyingtraction forces successively at intervals along the length andalternately on opposite sides of said stream, and causing'said tractionforces to attenuate and simultaneously crimp said stream.

2. The method of producing an interfelted fibrous glass body whichcomprises flowing a stream of molten glass, cooling the same to aviscous stream, simultaneously attenuating and crimping said stream bypassing the same interjacent intermeshing driven gears, and depositingsaid fibers as they emerge from said gears through a gaseous atmosphereupon an arresting surface.

3. The method of. producing an interfelted body of crimped fibers whichcomprises flowing a stream of molten glass, cooling the same to aviscous stream, simultaneously attenuating and crimping said stream bypassing said stream between intermeshing driven gear-shaped members toconvert the same into crimped fibrous form, passing said crimped g assfiber freely through a gaseous atmosphere to tangle and twist the samealong its length, and then depositing and accumulating said twisted andtangled crimped fiber upon an arresting surface.

4. The method of producing an interfelted body of crimped fibers whichcomprises flowing a multiplicity of streams of molten glass, cooling thesame to a viscous stream, simultaneously attenuating and crimping saidstreams by passing said streams between intermeshing driven gearshapedmembers to convert the same into crimped fibrous form, passing saidcrimped glass fibers freely through a gaseous atmosphere to tangle andtwist the same along their respective lengths, and then depositing andaccumulating said twisted and tangled crimped fibers upon an arrestingsurface.

5. The method of producing an interfelted body of crimped fibers whichcomprises flowing a multiplicity of streams of molten glass, cooling thesame to a viscous stream, simultaneously attenuating and crimping saidstreams by passing said streams between intermeshing driven gearshapedmembers to convert the same into crimped fibrous form, passing saidcrimped glass fibers freely through a gaseous atmosphere to tangle andtwist the same along their respective lengths, then depositing theaccumulating said twisted and tangled crimped fibers upon a travelingarresting surface, and passing said tangled mass between relativelymoving surfaces to increase the felted arrangement thereof.

6. The method of producing a crimped glass fiber which comprises flowinga stream of viscous glass, simultaneously attenuating, crimping andchilling said stream to solidified crimped form by passing the samebetween driven intermeshing gear-shaped members having a temperaturebelow the softening point of the glass.

7. The method of producing a crimped glass fiber which comprises flowinga stream of viscous glass, simultaneously attenuating, crimping andchilling said stream to solidified crimped form by passing the samebetween driven intermeshing gear-shaped members having a temperaturebelow the softening point of the glass, passing said crimped fiberfreely through a gaseous atmosphere, and depositing and accumulating thesame in mat formation upon a continually moving surface movingtransversely to the direction of movement of the stream through thecrimping rolls.

8. The method of producing fibrous glass which comprises flowing in adownward direction a stream of molten glass, cooling the same to aviscous stream, applying traction forces successively at spaced apartintervals along the length of and alternately on each side of saidstream, causing said traction forces during their application to pulland attenuate said stream as it flows to the point of application ofsaid forces and to simultaneously cause said forces as they are appliedat alternate intervals at opposite sides of said stream to bend saidstream back and forth, and then causing said stream after theapplication of said forces to fly freely through the atmosphere.

9. The method of producing fibrous glass which comprises flowing in adownward direction a stream of molten glass, cooling the same to aviscous stream, applying traction forces successively at spaced apartintervals along the length of and alternately on each side of saidstream, causing said traction forces during their application to pulland attenuate said stream as it flows to the point of application ofsaid forces and to simultaneously cause said forces as they are appliedat alternate intervals at opposite sides of said stream to bend saidstream back and forth, then causing said stream after the application ofsaid forces to fly freely through the atmosphere, and causing saidstream to gradually cool to solidity to form a crimped fiber.

10. The method of producing fibrous glass which comprises flowing in adownward direction a stream of molten glass, cooling the same to aviscous stream, applying traction forces successively at spaced apartintervals along the length of and alternately on each side of saidstream, causing said traction forces during their application to pulland attenuate said stream as it flows to the point of application ofsaid forces and to simultaneously cause said forces as they are appliedat alternate intervals at opposite sides of said stream to bend saidstream back and forth, then causing said stream after the application ofsaid forces to fiy freely through theatmosphere, and maintaining thetemperature of the stream sufficient that as it gradually cools incontact with the surrounding atmosphere it will retain plasticity untilthe stream is passing freely through the atmosphere after theapplication of said forces and is thus caused to bend itself haphazardlyand chill in such haphazard shape.

GAMES SLAYTER.

CERTIFICATE OF CORRECTION. Patent No. 2,250,272. February 1;, 19in.

GAMES SLAYTER.

It is hereby certified that error appears in' the printed specificationof the above numbered patent requiring correction as follows: Page 5,second column, line 24., claim 10, after the words and period "haphazardshape." and before the signature of the inventor, insert the followingas claim 11- 11. The method of producing crimped fibrous glass whichcomprises flowing an individual integral stream of viscous glass,applying traction forces successively at intervals along the length andalternately on opposite sides of the stream, and causing said tractionforces to simultaneously attenuate and crimp said individual integralstream into the form of a filament.

and that the said Letters Patent shouldbe read with this correctiontherein that the same may conform to the record of the case in thePatent Office.

Signed and sealed this 15th day of July, A. D. 19m.

Henry Van Arsdale, (Seal) Acting Commissioner of Patents.

